U.S. patent application number 10/010466 was filed with the patent office on 2002-06-27 for coating for treating substrates for ink jet printing including imbibing solution for enhanced image visualization and retention, method for treating said substrates, and articles produced threrefrom.
This patent application is currently assigned to Kimberly-Clark Worldwide, Inc.. Invention is credited to Bagwell, Alison Salyer, Branham, Kelly Dean, Kister, Mary Elizabeth, Zelazoski, Leonard Eugene.
Application Number | 20020081421 10/010466 |
Document ID | / |
Family ID | 26681215 |
Filed Date | 2002-06-27 |
United States Patent
Application |
20020081421 |
Kind Code |
A1 |
Bagwell, Alison Salyer ; et
al. |
June 27, 2002 |
Coating for treating substrates for ink jet printing including
imbibing solution for enhanced image visualization and retention,
method for treating said substrates, and articles produced
threrefrom
Abstract
An aqueous coating formulation containing solids, for enhancing
image visualization and retention of acid dye-based inks includes a
cationic polymer or copolymer, a fabric softener, urea, and
ammonium salts of multifunctional weak acids. Desirably the
ammonium salts are selected from the group consisting of ammonium
oxalate and ammonium tartrate.
Inventors: |
Bagwell, Alison Salyer;
(Cumming, GA) ; Branham, Kelly Dean; (Winneconne,
WI) ; Kister, Mary Elizabeth; (Cumming, GA) ;
Zelazoski, Leonard Eugene; (Kennesaw, GA) |
Correspondence
Address: |
KIMBERLY-CLARK WORLDWIDE, INC.
401 NORTH LAKE STREET
NEENAH
WI
54956
|
Assignee: |
Kimberly-Clark Worldwide,
Inc.
|
Family ID: |
26681215 |
Appl. No.: |
10/010466 |
Filed: |
October 26, 2001 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
60244262 |
Oct 30, 2000 |
|
|
|
Current U.S.
Class: |
428/32.1 |
Current CPC
Class: |
B41M 5/0017 20130101;
D06P 5/30 20130101 |
Class at
Publication: |
428/195 |
International
Class: |
B41M 005/00 |
Claims
What is claimed is:
1. An aqueous coating formulation containing solids, for enhancing
image visualization and retention of acid dye-based inks,
comprising: a) a cationic polymer or copolymer, b) a fabric
softener, c) urea, and d) ammonium oxalate.
2. The aqueous coating formulation of claim 1 wherein said cationic
polymer or copolymer is present in an amount between about 5 to 95%
of the total solids.
3. The aqueous coating formulation of claim 1 wherein said fabric
softener is present in an amount between about 5 to 20% of the
total solids.
4. The aqueous coating formulation of claim 1 further comprising a
latex binder.
5. The aqueous coating formulation of claim 4 wherein said latex
binder is present in an amount between about 0 to 80% of the total
solids.
6. The aqueous coating formulation of claim 1 wherein the urea is
present in an amount between about 2 and 5% of the total
solids.
7. The aqueous coating formulation of claim 1 wherein the ammonium
oxalate is present in an amount between about 5 and 10% of the
total solids.
8. The aqueous coating formulation of claim 1 further including
additives selected from the group including wetting agents,
defoamers, and surfactants.
9. The aqueous coating formulation of claim 1 further including at
least one tanning agent.
10. The aqueous coating formulation of claim 9 wherein said tanning
agent is either ethylene glycol monoethyl ether, thiodiethylene
glycol, or a combination thereof.
11. The aqueous coating formulation of claim 9, wherein said
tanning agent is present in an amount of between about 0.5 and 10%
of total solids.
12. An aqueous coating formulation containing solids, for enhancing
image visualization and retention of inks, comprising: a) a
cationic polymer or copolymer, b) a fabric softener, c) urea, and
d) ammonium oxalate.
13. The aqueous coating formulation of claim 12 further comprising
a tanning agent, said tanning agent being either ethylene glycol
monoethyl ether, thiodiethylene glycol, or a combination
thereof.
14. An aqueous imbibing solution, for enhancing image visualization
and retention of acid dye-based inks comprising: a) ammonium
oxalate, and b) urea.
15. The aqueous imbibing solution of claim 14, wherein said
ammonium oxalate is present between about 30 and 40% of the total
solids.
16. The aqueous imbibing solution of claim 14, wherein said urea is
present between about 50 and 70% of the total solids.
17. A method of treating a substrate so as to improve the adhesion,
colorfastness and washfastness of an acid dye-based ink jet ink
printed onto the substrate, and which substrate will be exposed to
a post-treatment step following printing, the method comprising the
steps of: a) providing a substrate, b) treating the substrate with
an aqueous coating formulation comprising a cationic polymer or
copolymer, a fabric softener, urea, and ammonium oxalate.
18. The method of claim 17 wherein said aqueous coating formulation
further includes a tanning agent.
19. The method of claim 17 wherein said tanning agent is selected
from either ethylene glycol monoethyl ether, thiodiethylene glycol,
or a combination thereof.
20. The method of claim 17 wherein said cationic polymer or
copolymer is present in an amount between about 5 to 95% of the
total solids.
21. The method of claim 17 wherein said fabric softener is present
in an amount between about 5 to 20% of the total solids.
22. The method of claim 17 wherein the aqueous coating formulation
further comprises a latex binder.
23. The method of claim 22 wherein said latex binder is present in
an amount between about 0 to 80% of the total solids.
24. The method of claim 17 wherein the urea is present in an amount
between about 2 and 5% of the total solids.
25. The method of claim 17 wherein the ammonium oxalate is present
in an amount between about 5 and 10% of the total solids.
26. An article produced by the method of claim 17.
27. A method of treating a substrate so as to improve the adhesion,
colorfastness and washfastness of an acid dye-based ink jet ink
printed onto the substrate, which will be exposed to a
post-treatment step following printing, the method comprising the
steps of: a) providing a substrate, b) treating the substrate with
an aqueous coating formulation comprising a cationic polymer or
copolymer, and a fabric softener, c) treating the substrate of step
b) with an aqueous imbibing solution of urea, and ammonium
oxalate.
28. A method of producing a printed substrate so as to improve the
adhesion, colorfastness and washfastness of an acid dye-based ink
jet ink printed onto the substrate, the method comprising the steps
of: a) providing a substrate, b) treating the substrate with an
aqueous coating formulation comprising a cationic polymer or
copolymer, a fabric softener, urea, and ammonium oxalate, c) drying
the substrate, d) printing on the substrate with an acid dye-based
ink, e) post-treating the printed substrate of step d).
29. The method of claim 28 wherein the aqueous coating formulation
includes a tanning agent.
30. A printed substrate produced in accordance with the method of
claim 28.
31. An aqueous coating formulation containing solids, for enhancing
image visualization and retention of inks, comprising: a) a
cationic polymer or copolymer, b) a fabric softener, c) urea, and
d) ammonium salts of multifunctional weak acids, selected from the
group consisting of ammonium oxalate and ammonium tartrate.
32. The aqueous coating formulation of claim 31 further comprising
a tanning agent.
33. The aqueous coating formulation of claim 32, said tanning agent
being either ethylene glycol monoethyl ether, thiodiethylene
glycol, or a combination thereof.
34. An aqueous imbibing solution, for enhancing image visualization
and retention of acid dye-based inks comprising: a) ammonium salts
of multifunctional weak acids, selected from the group consisting
of ammonium oxalate and ammonium tartrate, and b) urea.
35. A method of treating a substrate so as to improve the adhesion,
colorfastness and washfastness of an acid dye-based ink jet ink
printed onto the substrate, which will be exposed to a
post-treatment step following printing, the method comprising the
steps of: a) providing a substrate, b) treating the substrate with
an aqueous coating formulation comprising a cationic polymer or
copolymer, and a fabric softener, c) treating the substrate of step
b) with an aqueous imbibing solution of urea, and ammonium salts of
multifunctional weak acids, selected from the group consisting of
ammonium oxalate and ammonium tartrate.
36. A method of treating a substrate so as to improve the adhesion,
colorfastness and washfastness of an acid dye-based ink jet ink
printed onto the substrate, and which substrate will be exposed to
a post-treatment step following printing, the method comprising the
steps of: a) providing a substrate, b) treating the substrate with
an aqueous coating formulation comprising a cationic polymer or
copolymer, a fabric softener, urea, and ammonium salts of
multifunctional weak acids, selected from the group consisting of
ammonium oxalate and ammonium tartrate.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to coatings for treating ink
jet printable substrates, which are intended to receive images when
printed by ink jet printing devices. In particular, the present
invention relates to coatings for treating textile substrates for
ink jet printing, methods for treating said substrates, and
articles produced therefrom. Such methods facilitate the use of
such substrates in commonly available ink jet or laser printing
devices, such as wide or narrow format ink jet and laser
printers.
BACKGROUND OF THE INVENTION
[0002] Ink jet printing is a non-impact and non-contact printing
method in which an electronic signal controls and directs droplets
or a stream of ink that can be deposited on a wide variety of
substrates. Ink jet printing is extremely versatile in terms of the
variety of substrates that can be treated, as well as the print
quality and the speed of operation that can be achieved. In
addition, ink jet printing is digitally controllable. For these
reasons, ink jet methodology has been widely adopted for industrial
marking and labeling. In addition, ink jet methodology has also
found widespread use in architectural and engineering design
applications, medical imaging, office printing (of both text and
graphics), geographical imaging systems (e.g., for seismic data
analysis and mapping), signage, in display graphics (e.g.,
photographic reproduction, business and courtroom graphics, graphic
arts), and the like. Finally, ink jet printing has now also been
used to create an image on a variety of textile substrates. The use
of ink-jet printing to create an image on textile fabrics has
allowed for the rapid visualization of an aesthetic design on
fabric without the use of expensive and often wasteful screen
printing techniques. Such ink-jet printing methodology allows a
designer or production facility to visualize a finished design in
significantly less time than is usually necessary to burn a screen
image of the design by typical screen printing methodology.
[0003] Both dyes and pigments have been used as colorants for such
ink jet ink formulations. However, such materials do not always
adhere well to substrates to which the ink is applied. For example,
dyes may dissolve upon a substrate's contact with water. Thus
images applied employing ink jet methodology may tend to run or
smear upon repeated contact, or may be actually removed from the
printed surface if exposed to substantial quantities of aqueous
media (e.g., if an ink jet printed article is laundered). Moreover,
images applied employing ink jet methodology may also tend to fade
or washout upon prolonged exposure to visible, ultraviolet and/or
infrared light. Furthermore, dyes applied to textile substrates may
experience severe dye bleed upon application to the substrate.
Finally, the color intensity of the image printed on a textile
substrate using ink-jet methodology is often lacking in
vibrancy.
[0004] The nature of textile substrates also poses specific
problems when printing or imaging via ink jet print methods, which
are not found with common ink jet substrates (e.g. paper or coated
paper). For instance, the textile fibers can vary widely in
composition, with each composition presenting a unique set of
conditions for acceptable printing of the substrate. For example,
cotton substrates may be very absorbent, such as in the case of
aqueous-based inks. When ink is ejected from the ink channel of an
ink jet printing device, it is rapidly absorbed into the fibers of
the cotton substrate. Since these fibers are much larger than the
fibers typically found in paper substrates, the color density or
appearance of color brightness is significantly diminished due to
the lack of retention of the colorant at the surface of the fibers.
In addition, bleeding, mottle of the print pattern, and loss of
image sharpness or clarity can often result from printing on the
textile fabric itself.
[0005] Conversely, synthetic fibers such as polyester may be poorly
wet by the aqueous inks and such inks may be only retained in the
interstitial spaces between the fibers. This limited ink retention
also causes the print-quality related problems outlined above.
[0006] Furthermore, the permanence of the printed image on textile
fabrics is often achieved commercially by some post-printing curing
process such as heating, steaming, or chemical fixation. These
processes tend to be inefficient, requiring further washing and
drying steps to remove unfixed colorant from the fabric. It is
therefore desirable to enhance the permanence of the printed image
on ink jet printable substrates, either in the presence or absence
of a post-printing curing process step.
[0007] Polymeric materials are typically used commercially to
modify the properties of both natural and synthetic textile fibers
and substrates. These polymeric treatments may alter textile
appearance or hand, reduce shrinking, reduce flammability, or alter
other properties of the fiber or substrate. Treatments may even be
employed to enhance the ease of printing and/or print performance
when commercial printing processes, such as rotary screen printing,
are employed. For instance, polyethylene oxide has been used to
pretreat a starting cloth material so as to create an adequate
textile substrate for ink-jet printing. As disclosed in U.S. Pat.
No. 5,781,216 to Haruta et al., the use of polyethylene oxide
treated textile substrates are described as being highly capable of
providing images of great color depth with sufficient brightness
and sharpness, but free of objectionable color bleed. While Haruta
discloses such a polyethylene oxide pretreatment with a cationizing
agent, to thereby enhance the coloring ability of images, Haruta
requires such treatment to thereafter be cured by additional
heating, washing and drying steps.
[0008] Use of cationic polymers as part of a latex saturant in a
hydroentangled fibrous web is disclosed in PCT US 98 12712 to
Harris et al., which was published as WO99/00541. As described in
WO99/00541, latex saturation is typically followed by a drying step
or other curing aids.
[0009] Use of imbibing solutions with sodium bicarbonate, sodium
carbonate and urea are also known. Such imbibing solutions are
typically used by textile mills in ink pastes along with other
additives such as thickeners, and not in conjunction with coating
treatments on the textile substrates themselves prior to being
printed. The ink pastes are then rotary screen printed down onto
the fabric substrates. However, an ink jet paste delivery system
can not be used for ink jet printing because of the physical
constraints of the ink jet printer technology. The salts in the
pastes will corrode the ink jet printer heads. Use of ink pastes
are also a wasteful process. Furthermore, even with the use of such
pastes in a conventional screen printing process, the process
experiences a large amount of dye wash off following printing.
[0010] Accordingly, there is still a need in the art for ink jet
printable substrate coatings and treatment methods which provide
for high optical density with a minimum amount of bleeding on the
substrate during and after imaging from ink jet printers. There is
also a need in the art for such ink jet printable substrate
treatment methods which can be applied to textile fabric
substrates. In this regard, there is still a need in the art for
methods for treating fabrics for receiving ink-jet ink
formulations, which methods allow for improved colorfastness and
color intensity in a wide variety of textile substrates. Finally,
there is still a need in the art for such substrates which are not
dependent upon an ink curing step for construction.
SUMMARY OF THE INVENTION
[0011] In accordance with the present invention, it has been
discovered that the color density and quality of the printed image,
and the adhesion properties and/or colorfastness of acid and
reactive ink jet ink formulations when applied to a variety of ink
jet printable substrates, can be improved by treating the
substrates with cationic polymer coating formulations used in
conjunction with imbibing solutions, and in particular imbibing
solutions containing alkali materials, and urea for reactive-dye
based inks, ammonium salts and urea for acid dye-base inks. Such
alkali materials may be exemplified by such materials as sodium
hydroxide, sodium silicate, sodium trichloracetate, and potassium
carbonate. In particular the use of imbibing/coating
solutions/formulations containing ammonium salts of multifunctional
weak acids and urea has proven effective. Desirably the ammonium
salts are selected from the group consisting of ammonium oxalate
and ammonium tartrate. Ammonium oxalate and urea for treatment of
nylon/lycra type fabrics has proven particularly effective. In an
alternate embodiment, tanning agents can be used in conjunction
with the ammonium oxalate imbibing solution. Such tanning agents
may be exemplified by the group including ethylene glycol monoethyl
ether, and thiodiethylene glycol. It has been found that such
tanning agents help to improve the durability, in particular,
crockfastness with use of such imbibing solutions. A wide array of
textile fabric substrates can be treated to improve the
colorfastness and washfastness of ink jet ink formulations. The
treatment formulations include an aqueous coating formulation
containing solids and comprising a cationic polymer or copolymer, a
fabric softener, urea and alkali materials, for reactive dye based
inks, or in the alternative, the same cationic polymers, and fabric
softeners, but additionally urea and ammonium salts for acid dye
based inks. In particular the treatment formulations include about
5-95% cationic polymers or copolymers, and about 5-20% fabric
softeners. Alternatively, the formulations may also include about
0-80% of a polymeric latex binder so as to increase washfastness.
These percentages are based on solids. Total solids content for the
formulations typically range from about 10-50%. In an alternate
embodiment, use of cationic polymer coatings in conjunction with a
separate imbibing solution of either alkali materials and urea for
reactive dye classes may be used. In an alternate embodiment, use
of cationic polymer coating formulations in conjunction with a
separate imbibing solution of ammonium salt and urea for acid dye
classes may be used. The present methods provide pathways to the
fixation of dyes, irrespective of chemical class or textile fabric
substrate, and do so without the need of any further ink curing
process beyond drying under ambient conditions. In addition,
efficacy of post printing processes such as steaming or curing may
be enhanced by such formulations, reducing dye waste and further
enhancing color vibrancy. Also, fixation of pigment or colorant may
be enhanced by these formulations.
[0012] These and other features and advantages of the present
invention will become apparent after a review of the following
detailed description of the disclosed embodiments and the appended
claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIGS.1A-1C illustrates exemplary cationic polymers for use
in treatment formulations for substrates in accordance with the
present inventive methods.
[0014] FIG. 2 illustrates a schematic view of a dip and squeeze
process for treating ink jet printable substrates.
DETAILED DESCRIPTION OF THE INVENTION
[0015] In accordance with the present invention, there are provided
aqueous coatings and methods to improve the adhesion properties
and/or colorfastness/color density and washfastness of ink jet
printable substrates in the absence of a heating or post treatment
curing step, said methods including treating a textile substrate
with an aqueous coating formulation including cationic polymers or
copolymers and fabric softeners. In a desirable method, the method
comprises treating a textile substrate with an aqueous coating
formulation including about 5-95% cationic polymers or copolymers,
and about 5-20% fabric softeners. As has been stated earlier, these
percentages are percent of total solids, unless otherwise stated.
For the purposes of this application, the percent of the total
solids is calculated by dividing the dry parts value for a
particular component by the total dry parts of all of the
components of the formulation. The present invention is further
directed to a treated ink jet printable substrate wherein the
treatment comprises an aqueous coating formulation of cationic
polymers or copolymers and fabric softeners. A desirable embodiment
of the present invention is a treated ink jet printable substrate
wherein the aqueous coating treatment comprises about 5-95%
cationic polymers or copolymers, and about 5-20% fabric
softeners.
[0016] The cationic copolymers function in the formulation to
attract and fix oppositely charged anionic dye molecules to the
substrates, and in particular, textile fabric substrates. The
polymers or copolymers may contain reactive residues or groups
capable of crosslinking to the textile fibers, with themselves, or
with other components present in the formulation. Such cationic
resins may incorporate charge groups in the main polymer chains or
polymer backbones, or as side groups in the polymer chains. An
exemplary list of the structural formulas of such cationic polymers
are illustrated in FIGS. 1A-1C. The cationic polymers for use in
the coatings may include but are not limited to, polymers and
copolymers of diallyldialkyammonium monomers such as
diallyldimethylammonium chloride, cationic acrylate and acrylamide
such as acryloxyethyldimethylammonium chloride or
acrylamidoethyldimethylammon- ium chloride monomers, quarternized
vinylpyridine such as methyl vinylpyridine chloride, and
polyalkylamine polymers and copolymers. Co-monomers in such systems
may consist of ones which modify the flexibility, hydrophobicity,
or mechanical properties of the polymer molecule. In addition,
reactive and/or self-condensing monomers may be included to enhance
adhesion to the textile fiber or other components in the
formulation. Other examples of cationic polymers with charged
groups in the main chain include epihalohydrin-amine polymers such
as Reten.TM. 204 LS and Kymene.TM. 557 LX polymers of Hercules
Incorporated, of Wilmington, Delaware. A specific example of a
preferred cationic polymer resin is CP 7091 RV available from ECC
International of Roswell, Ga., with CP 7091 RV being a poly
(diallyldimethlammonium chloride-co-diacetone acrylamide).
[0017] Suitable fabric softeners which may be used in accordance
with the present inventive coatings/methods include, but are not
limited to, Varisoft 222 of the Goldschmidt Chemical Corporation of
Greenwich, Conn., Adogen 432 also of Goldschmidt, Accosoft 550-75
of the Stepan Company of Northfield, Ill., Alubrasoft Super 100 and
Alubrasoft 116 of the BASF Corporation, Specialty Chemicals
Division of Mt. Olive, N.J., and Ahcovel Base N-62 of ICI
Surfactants or Hodgson Texiles Chemical of Mt. Holly, N.C. Suitable
fabric softeners include those that are cationic or nonionic and
provide the attributes of print quality and image brightness to the
printed textile substrate. The fabric softener most suitable to a
particular textile fabric substrate varies by fabric substrate. For
instance, it has been found that the fabric softener Varisoft 222
performs better with cotton/banner fabric samples while Adogen 432
performs better with nylon/lycra samples.
[0018] In another embodiment of the present invention, the
previously described coating treatments or formulations for ink jet
printable substrates also include a latex binder in order to
further enhance the adhesion and/or waterfastness of colorants on
the textile fabric substrates. It has been found that coated ink
jet receptive substrates including a latex binder provide high
color density and saturation, superior print quality, reduction of
wicking or bleeding, and enhanced ink absorption. Furthermore, the
coating or treatment formulations provide a waterfast printed image
when printing via an ink jet printing process, without the
necessity of post-printing curing steps such as heating, steaming,
chemical fixation, or radiation. Likewise, the present invention is
also directed to a treated ink jet printable substrate wherein the
treatment comprises an aqueous coating formulation of cationic
polymers or copolymers, fabric softeners, and a latex binder. A
desirable embodiment of the present invention is a treated ink jet
printable substrate wherein the aqueous treatment formulation
comprises about 5-95% cationic polymers or copolymers, about 5-20%
fabric softeners and about 0-80% latex binder.
[0019] The treatment or coating formulations in this alternate
embodiment consist primarily of cationic polymers and copolymers,
fabric softeners and a water-insoluble polymer in the form of a
latex dispersion or emulsion. In particular, the treating
formulation may include about 0-80% polymeric latex binder
depending on the textile fabric substrate. The latex reinforcing
polymers may be either nonionic or cationic. By way of example
only, the latex materials may include vinylacetate,
ethylene-vinylacetate, acrylate, styrene, and styrene-acrylate
resins and other cationic or nonionic latexes. These resins may
include reactive or self cross-linking groups in addition to
inherent cationic functionality.
[0020] The aqueous coating formulations may also include other
additives which effect the appearance or tactile properties of the
finished substrate, such as optical brighteners. It should be
recognized that all of the stated percentages are based on solids
unless otherwise noted. Total solids content for the formulations
typically range from about 5-50%, but desirably range from about
5-32%. More desirably the total solids content for the formulations
range from about 25-28%.
[0021] Treatment formulations (compositions) for the textile
substrates are made by adding the above components from stock
solutions or dispersions, or as solids where appropriate, and
mixing to homogeneity. Application of the treatment formulation to
the textile substrates may be carried out by any known means to
those having ordinary skill in the art. For instance, fabric
substrates may be treated by a standard padding (dip and squeeze)
method and dried in a forced air oven, although any suitable drying
means of textiles known to those skilled in the art may be
employed. As can be seen in FIG. 2 showing a schematic view of a
dip and squeeze process 10 for treating ink jet printable
substrates, a textile substrate 20 is unwound from the incoming
roll 30 and is then dipped in a saturator tank/bath 40 for
sufficient time for it to become saturated with the treating
formulation. The textile substrate is then run through a
pressurized nip roll set 44 and 48. The pressure on the rolls
should be in the range of about 10-120 psig but desirably in the
range of about 10-65 psig, depending on the type of textile fabric
substrate utilized, and the total solids content of the treatment
formulations used. The pressurized nip rolls squeeze the coating
evenly onto the substrate so as to penetrate the surface of the
substrate. The rolls may be either rubber or steel, however a set
of rolls in which at least one roll being rubber is desirable.
Following passage through the nip pressure rolls, the textile
substrate is coursed through a drying means 50. The drying means
may include a tenter frame for holding the textile substrate, and
may itself encompass multiple consecutive drying means depending on
the nature of the substrate to be dried. The drying temperature is
desirably in the range from about 200.degree. F. to 325.degree. F.,
desirably between about 220 to 250.degree. F. The typical time for
drying is between about 30 seconds and 3 minutes. Following drying,
the finished treated textile substrate is taken up on a wind up
roll 52. The textile substrate may be rolled up for storage or
moved to a second lamination process in preparation for ink jet
printing. The textile substrate may be laminated to a carrier
backing for ease of printing.
[0022] Using this application method, dry pick-up ratios of the
textile substrate may vary from about 0.5% to about 50%. Desirably,
the dry pick-up ratios may vary from about 3 to about 20%. More
desirably, the dry pick-up ratios may vary from about 6 to about
15%. Wet pick-up ratios for the textile substrates are typically
between about 30-150%. Desirably such wet pick-up ratios are
between about 80-120%. Desirably for Dacron banners, the wet pick
up ratios are between about 40-120%. These terms are defined by
equations which follow.
[0023] Substrates which may be treated in accordance with the
present inventive methods are varied and include paper, fabric,
films, and the like, although textile fabric substrates are
preferred. Such fabrics may include cotton, silk, wool, polyester,
rayon, nylon, and blends thereof. Furthermore, the disclosed ink
jet substrates may provide the benefits disclosed herein with or
without further post-printing curing steps involving the use of
heat, radiation or pressure. Ideally such treated substrates
provide adhesion and/or colorfastness of the colorant with only
ambient or room temperature curing or drying of the printed image.
It should be noted however, that while not being necessary for the
process, a post printing curing step may further enhance the
colorfastness and washfastness of the printed image on the
substrate. The basis weight of the various fabrics which may be
treated by these formulations may range from about 2 ounces per
square yard (osy) to about 9 osy.
[0024] Dye classes which may be used in ink jet printers to be
printed on such substrates include acid dyes, reactive dyes, direct
dyes, azoic dyes, sulfur dyes, modified dyes, polymeric dyes,
copolymerized dyes or other classes of colorants known to those
skilled in the art. Furthermore, pigment colorants may be used in
the ink jet printers to be printed on such substrates.
Additionally, it has been found that when such substrate is printed
with ink jet inks containing additives, such as those described in
U.S. Application bearing Ser. No. 09/109,681 filed Jul. 2, 1998 and
U.S. Pat. No. 5,897,694 incorporated herein by reference in its
entirety, such substrate treatments may be enhanced so as to
provide enhanced colorfastness and washfastness.
[0025] In a further embodiment of the present invention, such
previously described treatment formulations may be used in a method
to treat banner textile fabric substrates. Such substrate materials
include 100% cotton, 100% polyester, 100% silk, nylon, rayon and
blended materials, such as blends of cotton and polyester, as well
as nonwoven materials. For instance, it has been found that the
pretreatment of banner textile fabric substrate with an aqueous
coating formulation including cationic polymers, fabric softeners,
and latex polymer binders in accordance with the previously
described methods enable the banner substrates to be ink jet
printable, with improved colorfastness/color density and
washfastness, and with reduced color bleed. Likewise, the present
invention is also directed to a treated ink jet printable banner
substrate wherein the treatment comprises a formulation of cationic
polymers or copolymers, fabric softeners, and an optional latex
binder. A desirable embodiment of the present invention is a
treated ink jet printable banner substrate wherein the aqueous
treatment formulation includes between about 5-95% cationic
polymers or copolymers, between about 5-20% fabric softeners and
between about 0-80% latex binder.
[0026] In accordance with yet another embodiment of the present
invention, there are provided articles produced by the above
described methods, employing treated textile substrates as
described herein. Such articles may include for example banners,
wall coverings and other home furnishing products. Thus according
to the present invention, ink jet printed images applied to a
treated substrate as described herein, resists removal of said
image from said substrate, even upon repeated contact of the
printed substrate with water. Such repetitive contact can be the
result of normal handling of an article, accidental exposure to
liquid, and routine laundering of the article. When articles
according to the present invention comprise a treated substrate
containing an ink jet image printed thereon, the resulting image
adheres sufficiently to said substrate to resist removal therefrom
upon washing of said article. The present invention including each
of the various embodiments is further described by the examples
which follow. Such examples however, are not to be construed as
limiting in any way either the spirit or the scope of the present
invention.
Preliminary Examples
[0027] Textile substrate samples were first printed with a test
pattern using a commercial ink jet printer utilizing commercial ink
jet inks containing acid, reactive, and/or direct dyes. Color
density, color bleed, and print quality were evaluated on the
samples as printed. These textiles included cotton poplin textile
substrates. Duplicates of both sets of samples were washed using a
washing method as described. Color density, color bleed, print
quality or appearance, and color permanence were evaluated using
the washed samples. Data from the preliminary examples is expressed
in Table 1 which follows.
1TABLE 1 COLORFAST INK FABRIC HEAT EVAL. WATER DETERG. INK ADDITIVE
TREATMENT TREATMENT DELTA E DELTA E Encad none none none <56
<82 GA Encad none 0.5% CP none <29 <66 GA 7091 RV Encad
none 1.0% CP none <28 <50 GA 7091 RV Encad none 2.0% CP none
<27 <32 GA 7091 RV
[0028] CP 7091 RV=is a diallyldimethyammonium chloride/diacetone
acrylamide copolymer, ECC International. Encad GA inks employ
standard monomeric dyes. Samples were hand washed. The sampling
tested magenta inks. Delta E was calculated in the samples
utilizing the spectrodensitometer and equation described below. The
sampling was produced using a dip and squeeze method, as previously
described. As can be seen, the coating in the Preliminary Examples
only included cationic polymer in the aqueous formulation. Percent
represents percent solution.
[0029] A second more rigorous set of tests and examples were run on
a variety of fabric substrates. These textile fabric substrates
include the materials listed in Table 2.
2TABLE 2 BASIS BASIS WEIGHT Con- WEIGHT SI UNITS FABRIC STYLE
struction SOURCE (OZ/YD.sup.2) (G/M.sup.2) Polyester PP 6248 Plain
Fisher 3.8 128.8 poplin Weave Textiles Polyester PS241 Satin Fisher
4.1 139.0 satin Textiles 250 Denier 250 Plain Fisher 3.2 108.5
Dacron Poly. Dacron Weave Textiles Cotton 9680 " Lorber 6.5 220.39
Poplin Indust. Cotton 5118 Knit Lorber 8.2 277.9 Jersey Indust.
Cotton Plain Cranston 7.0 237.2 Sheeting Weave Mills .16 mm Silk
12104 Satin U.S. Silk, 2.0 67.8 Charmeuse Inc. Silk crepe 14654
Crepe U.S. Silk, 2.3 78.0 dechine .18 Inc. mm Polyester NOFU7-
Crepe Scher 3.8 128.8 Georgette 6058A Georgette Fabrics, Inc.
Polyester Knit Scher 3.2 108.5 stretch Fabrics, crepe Inc.
Poly./lycra 55153 Knit Guilford 5.5 186.4 Blend Mills Nylon/lycra
56062 Knit Guilford 4.0 135.6 blend Mills Rayon YWSR Crepe U.S.
Silk, 3.5 118.6 1352 Inc. U.S. Silk, Inc. is located in New York,
NY. Guilford Mills is located in New York, NY. Scher Fabrics, Inc.
is located in New York, NY. Cranston Mills is located in Cranston,
RI. Lorber Industries is located in Gardena, CA. Fisher Textiles is
located in Indian Trail, NC.
Conditions for Second Set of Examples
[0030] Printing Steps
[0031] In each of the following examples, treated textile samples
were printed using an Encad Pro E (@ 300 dpi) ink jet printer
obtained from Encad Inc. of San Diego, Calif. Encad GA, GS, or GO
inks were employed using 4-Pass Enhanced Print Mode, that is with
the printer passing over the textile substrate four times. In some
instances, as noted as double strike in data tables, the printing
head was preheated and option identified as number "7" was selected
on the printer. This option enabled more ink to be expelled from
the printer onto the substrates. Dyes in the inks consisted of
reactive, acid, and/or direct dyes and are described in Table
3.
3TABLE 3 Inks Used GS Ink Color Order # Dyes Cyan 209489 Direct
Magenta 208163-2 Acid/Reactive Yellow 208163-3 Acid Black 208163-4
Direct GO Ink Color Order # Cyan 208165-1 Pigment Magenta 208165-2
Pigment Yellow 208165-3 Pigment Black 208165-4 Pigment GA Ink Color
Order # Dyes Cyan 209491 Direct Magenta 209490 Acid Yellow 208164-3
Acid Black 208164-4 Direct
[0032] Sample sizes were typically 11 by 15 inches. Additionally, a
floral three color print, using lavender, green and magenta was
used for testing, of approximately 14 by 25 inches in size. Where
it was difficult to distinguish between shades of green, a neutral
portion (that is free of ink) of the sample was also evaluated.
[0033] Color Measurements
[0034] L* a* b* color values measurements (CIE 1976 Commission
Internationale de l'Eclairage) and optical density were made of the
printed textile substrates using an X-Rite 938 Spectrodensitometer
(D65/10.degree.) using CMY filters, in accordance with the
operator's manual. The X-Rite spectrodensitometer was obtained from
the X-Rite Corporation of Grandville, Mich. Average optical
densities were taken as the sum of the average of three
measurements using each filter. Delta E is calculated in accordance
with the following equation:
.DELTA.E=SQRT
[(L*standard-L*sample).sup.2+(a*standard-a*sample).sup.2+(b*-
standard-b*sample).sup.2]
[0035] The higher the Delta E, the greater the change in color
intensity. Unless the color's intensity is increased by a curing
step, a large increase in delta E would typically be indicative of
fading. The testing was in accordance with ASTM DM 224-93 and ASTM
E308-90. Where values for delta E are less than 3.0, it is
generally accepted that such color change cannot be observed with
the human eye. A detailed description of spectrodensitometer
testing is available in Color Technology in the Textile Industry,
2.sup.nd Edition, Published 1997 by AATCC (American Association of
Textile Chemists & Colorists).
[0036] Washing Method for Textile Samples
[0037] When indicated, textile samples were washed using the
following method. Samples were placed in an appropriate size beaker
or container such as a one liter beaker. Samples were then placed
under cold running water (between approximately 10-20.degree. C.)
for approximately two minutes. The cold water was then drained from
the textile samples. The beakers were then refilled with hot water
(between approximately 40-50.degree. C.), and one ounce of
detergent (Synthrapol.RTM. per gallon of water was added to the
beakers).
[0038] The textile samples were then washed out for approximately
five minutes and then rinsed and drained of remaining water.
Finally, the textile samples were rinsed with warm water (of
between approximately 25-30.degree. C.) for two minutes followed by
a rinse with cold water (of between approximately 10-20.degree. C.)
for approximately one more minute.
[0039] Typically, although not necessarily required for curing, a
second set of samples were printed and subsequently steamed using a
laboratory steamer for comparison. For the purposes of the
examples, if a colorfastness level is characterized as poor,
bleeding or wicking has occurred. If a washfastness level has been
characterized as poor, the image has washed out. If a colorfastness
and washfastness level has been characterized as good, the color
vibrancy and image retention is noticeably better than the poor
level. If the colorfastness and washfastness levels are
characterized as excellent, the color properties and vibrancy are
the highest levels with the highest color density.
EXAMPLES
[0040] It should be noted that for each of the following examples,
the textile substrate had been laminated to an adhesive coated
paper backing which was obtained from American Builtrite, Inc.
under the designation ProtecRite.RTM. 6798 prior to printing to
enable the substrate to be easily coursed through the printer. The
substrates were then removed from the backing prior to washing.
Adhesive coated backing papers identified by the designation 6798
include a paper having a nominal thickness of 5.4 mil., an initial
adhesion value of 27 oz/in, a tensile strength of 16 lbs/in the
machine direction, and an elongation capability of 10% in the
machine direction. The batch formulations utilized are described in
the following example summaries.
Example 1
[0041] Cationic copolymer CP 7091 RV (ECC International),
poly(diallyidimethylammonium chloride-co-diacetone acrylamide), was
obtained in a 49.3% stock solution in water. 20.3 wet parts of this
solution (10 dry parts, or approximately 90-91% of the total dry
parts) were added to 70.3 parts water with mixing. 1.1 wet part (1
dry part, or approximately 9% of the total dry parts) Varisoft.RTM.
222 fabric softener (90% in water) was added and the entire
solution was mixed until homogeneous. This formulation was used to
treat 100% cotton poplin via a padding application and dried as
previously described. A portion of this sample was laminated to an
adhesive paper carrier, printed with an ink jet printer and dried
under ambient conditions. The properties of the sample were
evaluated for quality of the printed image, ink retention, and
color density or saturation under the following conditions: 1)
immediately after printing, 2) after printing and washing, 3) after
printing and steaming, 4) after printing, steaming and washing. The
printed samples exhibited superior image quality with little or no
bleed, excellent ink retention, and excellent color density.
Samples that were steamed exhibited excellent enhancement of color
and appearance. Washfastness of steamed samples and samples not
post-treated with steam exhibited moderate retention of color when
washed. This Example utilized the GS ink set.
Example 2
[0042] The formulation employed in Example 1 was used to treat a
100% polyester georgette fabric. Results for this fabric were
similar to those obtained in Example 1. This Example utilized the
GS ink set and GO ink set.
Example 3
[0043] 20.3 wet parts (cationic copolymer CP 7091 RV (ECC
International) (49.3% in water)(10 dry parts or approximately
90-91% of the total dry parts) was added to 48.9 parts water with
mixing. 22.5 wet parts Adogen.RTM. 432 fabric softener (4.4% in
water)(1 dry part, or approximately 9% of the total dry parts) was
added and the entire solution was mixed until homogeneous. This
formulation was used to treat 100% cotton poplin via a conventional
padding application and dried. The sample was printed and evaluated
using the process described in Example 1. The printed sample
exhibited superior image quality with little or no bleed, excellent
ink retention, and excellent color density. Samples that were
steamed exhibited excellent enhancement for color and appearance.
Washfastness of steamed samples and samples not post-treated with
steam exhibited moderate retention of color when washed. This
Example utilized the GS ink set.
Example 4
[0044] The formulation employed in Example 3 was used to treat a
100% silk charmeuse fabric. Results for this fabric were similar to
those obtained in Example 3. This Example utilized the GS ink
set.
Example 5
[0045] The formulation employed in Example 3 was used to treat a
100% silk crepe de chine fabric. Results for this fabric were
similar to those obtained in Example 3. This Example utilized the
GS ink set.
Example 6
[0046] 20.3 wet parts cationic copolymer CP 7091 RV (ECC
International) (49.3% in water) was added to 48.9 parts water with
mixing. 11.3 wet parts Adogen.RTM. 432 fabric softener (4.4% in
water) and 11.3 wet part Varisoft.RTM. 222 (4.7% in water) was
added and the entire solution was mixed until homogeneous. This
formulation was used to treat 100% cotton poplin via a conventional
padding application and dried. The sample was printed and evaluated
using the process described in Example 1. The printed sample
exhibited superior image quality with little or no bleed, excellent
ink retention, and excellent color density. Samples that were
steamed exhibited excellent enhancement for color and appearance.
Washfastness of steamed samples and samples not post-treated with
steam exhibited moderate retention of color when washed. This
Example utilized the GS ink set.
Example 7
[0047] A treatment composition was formulated as in Example 6,
substituting 23.1 wet parts Accosoft.RTM. 550 fabric softener (4.3%
in water) (1 dry part, or approximately 9% of the total dry parts)
for parts Adogen.RTM. 432 fabric softener. The cationic polymer
made up 10 dry parts or approximately 90-91% of the total dry
parts. The wet parts of water constituted approximately 48.2 parts.
This formulation was used to treat 100% cotton poplin via a padding
application and dried. The sample was printed and evaluated using
the process described in Example 1. The printed sample exhibited
superior image quality with little or no bleed, excellent ink
retention, and excellent color density. Samples that were steamed
exhibited excellent enhancement for color and appearance.
Permanence of color to washing of steamed was dramatically
increased compared to untreated samples. Some enhancement of
colorfastness was achieved without steaming. This Example utilized
the GS ink set.
Example 8
[0048] The formulation employed in Example 7 was used to treat
85/15 nylon/lycra blend fabric. Results for this fabric were
similar to those obtained in Example 7. This Example utilized the
GS ink set.
Example 9
[0049] The formulation employed in Example 7 was used to treat a
100% silk charmeuse fabric. Results for this fabric were similar to
those obtained in Example 7. This Example utilized the GS ink
set.
Example 10
[0050] A treatment composition was formulated as in Example 3,
substituting 22.7 wet parts Alubrasoft.RTM. Super 100 fabric
softener (4.4% in water)(1 dry part or approximately 9% of the
total dry parts) for parts Adogen.RTM. 432 fabric softener. The
formulation included 20.3 wet parts of 7091 RV (10 dry parts, or
approximately 90-91% of the total dry parts), and 48.7 parts water.
This formulation was used to treat cotton poplin via a conventional
padding application and dried. The sample was printed and evaluated
using the process described in Example 1. The printed sample
exhibited superior image quality with little or no bleed, excellent
ink retention, and excellent color density. Samples that were
steamed exhibited excellent enhancement for color and appearance.
Permanence of color to washing of steamed samples was dramatically
increased compared to untreated samples. Some enhancement of
colorfastness was achieved without steaming. The Example utilized
the GS ink set.
Example 11
[0051] The formulation employed in Example 10 was used to treat
85/15 nylon/lycra blend fabric. Results for this fabric were
similar to those obtained in Example 10. The Example utilized the
GS ink set.
Example 12
[0052] The formulation employed in Example 10 was used to treat a
100% silk charmeuse fabric. Results for this fabric were similar to
those obtained in Example 10. The Example utilized the GS ink
set.
Example 13
[0053] A treatment composition was formulated as in Example 3,
substituting 8.8 wet parts Ahcovel.RTM. fabric softener (11.3% in
water)(1 dry part, or approximately 9% of the total dry parts) for
parts Adogen.RTM. 432 fabric softener. The formulation included
20.3 wet parts of 7091 RV (10 dry parts, or approximately 90-91% of
the total dry parts), and 62.5 parts water. This formulation was
used to treat 100% cotton poplin via a padding application and
dried. The sample was printed and evaluated using the process
described in Example 1. The printed sample exhibited superior image
quality with little or no bleed, excellent ink retention, and
excellent color density. Samples that were steamed exhibited
excellent enhancement for color and appearance. Permanence of color
to washing of steamed samples was dramatically increased compared
to untreated samples. Good enhancement of colorfastness was
achieved without steaming. The Example utilized the GS ink set.
Example 14
[0054] Cationic polymer CP 261 LV (ECC International),
Poly(diallyldimethylammonium), was obtained in a 43.0% stock
solution in water. 23.3 wet parts of this solution (10 dry parts,
or approximately 90-91% of the total dry parts) was added to 47.1
parts water with mixing. 21.3 wet parts Varisoft.RTM. 222 fabric
softener (4.7% in water)(1 dry part, or approximately 9% of the
total dry parts) was added and the entire solution was mixed until
homogeneous. This formulation was used to treat 100% cotton poplin
via a padding application and dried. The sample was printed and
evaluated using the process described in Example 1. The printed
sample exhibited superior image quality with little or no bleed,
excellent ink retention, and excellent color density. Samples that
were not steamed exhibited moderate retention of color when washed.
Some enhancement of colorfastness was achieved. Samples that were
steamed exhibited excellent enhancement for color and appearance.
Washfastness of steamed samples and samples not post-treated with
steam exhibited moderate retention of color when washed. The
Example utilized the GS ink set.
Example 15
[0055] 28.8 wet parts of a solution containing 80% ethoxylated
polyethylenimine (34.7% in water)(10 dry parts, or approximately
90-91% of the total dry parts) was combined with 41.6 parts water
with mixing. 21.3 wet parts Varisoft.RTM. 222 fabric softener (4.7%
in water) (1 dry part, or approximately 9% of the total dry parts)
were added and the entire solution was mixed until homogeneous.
This formulation was used to treat 100% cotton poplin via a padding
application and dried. The sample was printed and evaluated using
the process described in Example 1. The printed sample exhibited
superior image quality with little or no bleed, excellent ink
retention, and excellent color density. Samples that were not
steamed exhibited moderate retention of color when washed. Some
enhancement of colorfastness was achieved. Samples that were
steamed exhibited excellent enhancement for color and appearance.
Washfastness of steamed samples and samples not post-treated with
steam exhibited moderate retention of color when washed. The
Example utilized the GS ink set.
Example 16
[0056] 50.7 wet parts cationic copolymer CP 7091 RV (ECC
International) (49.3% in water)(25 dry parts, or approximately
18-19% of the total dry parts) was added to 656 parts water with
mixing. 90.6 wet parts Airflex.RTM. 540 latex emulsion
(ethylene-vinyl acetate copolymer, 55.2% in water)(50 dry parts, or
approximately 37% of the total dry parts) of AirProducts and
Chemicals Inc. of Allentown, Pennsylvania, 114.9 wet parts
PrintRite.RTM. 595 acrylic emulsion (Noveon Performance Coatings,
43.5% in water)(50 dry parts, or approximately 37% of the total dry
parts), and 212.8 wet parts Varisoft.RTM. 222 fabric softener (4.7%
in water)(10 dry parts, or approximately 7% of the total dry parts)
were added and the entire solution was mixed until homogeneous.
This formulation was used to treat 100% Cotton Poplin via a padding
application and dried. The sample was printed and evaluated using
the process described in Example 1. The printed sample exhibited
superior image quality with little or no bleed, excellent ink
retention, and excellent color density. Samples that were not
steamed exhibited good retention of color when washed. Samples that
were steamed exhibited excellent enhancement for color and
appearance. Permanence of color to washing was dramatically
increased compared to untreated samples. The Example utilized the
GS ink set.
Example 17
[0057] The formulation employed in Example 16 was used to treat a
100% cotton Jersey knit fabric. Results for this fabric were
similar to those obtained in Example 16. The trial utilized the GS
ink set.
Example 18
[0058] The formulation employed in Example 16 was used to treat an
85/15 nylon/lycra blend fabric. Results for this fabric were
similar to those obtained in Example 16. The Example utilized the
GS ink set.
Example 19
[0059] The formulation employed in Example 16 was used to treat a
100% silk charmeuse fabric. Results for this fabric were similar to
those obtained in Example 16. The Example utilized the GS ink
set.
Example 20
[0060] The formulation employed in Example 16 was used to treat a
100% silk crepe de chine fabric. Results for this fabric were
similar to those obtained in Example 16. The Example utilized the
GS ink set.
Example 21
[0061] 50.7 wet parts cationic copolymer CP 7091 RV (ECC
International) (49.3% in water)(25 dry parts, or approximately
18-19% of the total dry parts) was added to 656.0 parts water with
mixing. 90.6 wet parts Airflex.RTM. 540 latex emulsion
(ethylene-vinyl acetate copolymer, 55.2% in water)(50 dry parts, or
approximately 37% of the total dry parts), 114.9 wet parts
PrintRite.RTM. 591 acrylic emulsion (Noveon Performance Coatings,
43.5% in water)(50 dry parts, or approximately 37% of the total dry
parts), and 212.8 wet parts Varisoft.RTM. 222 fabric softener (4.7%
in water) (10 dry parts, or approximately 7% of the total dry
parts) were added and the entire solution was mixed until
homogeneous. This formulation was used to treat 100% cotton poplin
via a padding application and dried. The sample was printed and
evaluated using the process described in Example 1. The printed
sample exhibited superior image quality with little or no bleed,
excellent ink retention, and excellent color density. Samples that
were not steamed exhibited good retention of color when washed.
Samples that were steamed exhibited excellent enhancement for color
and appearance. Permanence of color to washing was dramatically
increased compared to untreated samples. Little measurable washout
was detected. The Example utilized the GS ink set.
Example 22
[0062] The formulation employed in Example 21 was used to treat a
100% cotton Jersey Knit fabric. Results for this fabric were
similar to those obtained in Example 21. The Example utilized the
GS ink set.
[0063] A sample result for Delta E values is reflected in the
following Table 4. It should be recognized that values for delta E
can range from 0 to 100 with the lower values being preferred for
demonstrating minimum loss of color vibrancy/fading. Delta E values
are a comparison of "treated and washed" or "treated and dry
cleaned" samples versus "treated" samples. In some instances, Delta
E values are a comparison of "treated, steamed, and washed"
samples, versus "treated" samples. Textile fabrics which were
capable of being printed without a coating experienced poor
printing attributes and experienced total washout (with a Delta E
theoretically at approximately 100). The following data applies to
a Cranston Cotton sample, which was treated with a coating
formulation as described in Example 21.
4 TABLE 4 L* A* B* DELTA E TREATED Magenta 58.0 30.8 -17.6 standard
Treated & Washed Magenta 59.0 37.2 -22.9 8.3
Example 23
[0064] The formulation employed in Example 21 was used to treat a
100% silk charmeuse fabric. Results for this fabric were similar to
those obtained in Example 21. This substrate was cleaned using
commercial dry cleaning facilities and sample results are reflected
in the following Table 5. The Example utilized the GS ink set.
5 TABLE 5 L* A* B* DELTA E TREATED Magenta 46.9 54.8 -5.2 standard
Black 1 29.5 1.8 0.5 standard Yellow 83.6 5.0 91.8 standard Cyan
61.8 -27.9 -31.2 standard Dry Cleaned Magenta 44.7 54.6 -5.0 2.3
Black 1 27.7 1.4 -.03 2.0 Yellow 82.4 4.7 90.3 1.9 Cyan 60.8 -28.5
29.8 1.8
Example 24
[0065] 10.1 wet parts cationic copolymer CP 7091 RV (ECC
International) (49.3% in water)(5 dry parts, or approximately 45%
of the total dry parts) was added to 48.8 parts water with mixing.
11.5 wet parts PrintRite.RTM. 591 acrylic emulsion (Noveon
Performance Coatings, 43.5% in water)(5 dry parts, or approximately
45% of the total dry parts), and 21.3 wet parts Varisoft.RTM. 222
fabric softener (4.7% in water) (1 dry part, or approximately 9% of
the total dry parts) were added and the entire solution was mixed
until homogeneous. This formulation was used to treat 100% cotton
poplin via a padding application and dried. The sample was printed
and evaluated using the process described in Example 1. The printed
sample exhibited superior image quality with little or no bleed,
excellent ink retention, and excellent color density. Samples that
were not steamed exhibited good retention of color when washed.
Samples that were steamed exhibited excellent enhancement for color
and appearance. Washfastness of steamed samples and samples not
post-treated with steam exhibited moderate retention of color when
washed. The Example utilized the GS ink set.
Example 25
[0066] The formulation employed in Example 24 was used to treat an
85/15 nylon/lycra blend fabric. Results for this fabric were
similar to those obtained in Example 24. The Example utilized the
GS ink set.
Example 26
[0067] 10.1 wet parts cationic copolymer CP 7091 RV (ECC
International) (49.3% in water)(5 dry parts, or approximately 45%
of the total dry parts) was added to 48.8 parts water with mixing.
11.5 wet parts PrintRite.RTM. 595 acrylic emulsion (Noveon
Performance Coatings, 43.5% in water)(5 dry parts, or approximately
45% of the total dry parts), and 21.3 wet parts Varisoft.RTM. 222
fabric softener (4.7% in water)(1 dry part, or approximately 9% of
the total dry parts) were added, and the entire solution was mixed
until homogeneous. This formulation was used to treat 100% cotton
poplin via a padding application and dried. The sample was printed
and evaluated using the process described in Example 1. The printed
sample exhibited superior image quality with little or no bleed,
excellent ink retention, and excellent color density. Samples that
were not steamed exhibited good retention of color when washed.
Samples that were steamed exhibited excellent enhancement for color
and appearance. Permanence of color to washing was dramatically
increased compared to untreated samples. The Example utilized the
GS ink set.
Example 27
[0068] The formulation employed in Example 26 was used to treat an
85/15 nylon/lycra blend fabric. The printed sample exhibited
superior image quality with little or no bleed, excellent ink
retention, and excellent color density. Permanence of color to
washing was not improved in these samples. The Example utilized the
GS ink set.
Example 28
[0069] 10.1 wet parts cationic copolymer CP 7091 RV (ECC
International) (49.3% in water)(5 dry parts, or approximately 45%
of the total dry parts) was added to 51.2 parts water with mixing.
9.1 wet parts Airflex.RTM. 540 latex emulsion (ethylene-vinyl
acetate copolymer, 55.2% in water)(5 dry parts, or approximately
45% of the total dry parts), and 21.3 wet parts Varisoft.RTM. 222
fabric softener (4.7% in water)(1 dry part, or approximately 9% of
the total dry parts) were added and the entire solution was mixed
until homogeneous. This formulation was used to treat 100% cotton
poplin via a padding application and dried. The sample was printed
and evaluated using the process described in Example 1. The printed
sample exhibited superior image quality with little or no bleed,
excellent ink retention, and excellent color density. Samples that
were not steamed exhibited good retention of color when washed.
Samples that were steamed exhibited excellent enhancement for color
and appearance. Permanence of color to washing was dramatically
increased compared to untreated samples. The Example utilized the
GS ink set.
Example 29
[0070] The formulation employed in Example 28 was used to treat an
85/15 nylon/lycra blend fabric. The printed sample exhibited
superior image quality with little or no bleed, excellent ink
retention, and excellent color density. Permanence of color to
washing was not improved in these samples. The Example utilized the
GS ink set.
Example 30
[0071] 50.7 wet parts cationic copolymer CP 7091 RV (ECC
International) (49.3% in water)(25 dry parts, or approximately
18-19% of the total dry parts) was added to 881.9 parts water with
mixing. 181.3 wet parts Airflex.RTM. 540 latex emulsion
(ethylene-vinyl acetate copolymer, 55.2% in water)(100 dry parts,
or approximately 74% of the total dry parts), and 11.1 wet parts
Varisoft.RTM. 222 fabric softener (90% in water)(10 dry parts, or
approximately 7% of the total dry parts) were added and the entire
solution was mixed until homogeneous. This formulation was used to
treat a 250 denier polyester/cotton banner fabric via a padding
application and dried. The sample was printed as described in
Example 1. The printed samples exhibited superior image quality
with little or no bleed, excellent ink retention, and excellent
color density. Permanence of color to washing was dramatically
increased without steaming or other steps.
Example 31
[0072] 50.7 wet parts cationic copolymer CP 7091 RV (ECC
International) (49.3% in water) (25 dry parts, or approximately
18-19% of the total dry parts) was added to 878.0 parts water with
mixing. 181.3 wet parts Airflex.RTM. 540 latex emulsion
(ethylene-vinyl acetate copolymer, 55.2% in water)(100 dry parts,
or approximately 74% of the total dry parts), and 15.0 wet parts
Adogen.RTM. 432 fabric softener (66.7% in water)(10 dry parts, or
approximately 7% of the total dry parts) were added and the entire
solution was mixed until homogeneous. This formulation was used to
treat a 250 denier polyester/cotton banner fabric via a padding
application and dried. The sample was printed as described in
Example 1. The printed samples exhibited superior image quality
with little or no bleed, excellent ink retention, and excellent
color density. Permanence of color to washing was dramatically
increased without steaming or other steps.
[0073] Textile samples in Examples 30 through 35 were printed with
the Encad GO ink set obtained from the Encad Inc.
Example 32
[0074] The formulation employed in Example 31 was used to treat a
polyester poplin fabric. The printed sample exhibited superior
image quality with little or no bleed, excellent ink retention, and
excellent color density. Permanence of color to washing was
dramatically increased without steaming or other curing steps.
Example 33
[0075] The formulation employed in Example 31 was used to treat a
polyester satin fabric. The printed sample exhibited superior image
quality with little or no bleed, excellent ink retention, and
excellent color density. Permanence of color to washing was
dramatically increased without steaming or other curing steps. In
addition, the sample possessed excellent visual color reflectivity.
Such quality may be observed visually or measured through diffuse
reflectance methods.
Example 34
[0076] The formulation employed in Example 31 was used to treat a
polyester poplin fabric. The printed sample exhibited superior
image quality with little or no bleed, excellent ink retention, and
excellent color density. Permanence of color to washing was
dramatically increased without steaming or other steps.
Example 35
[0077] The formulation employed in Example 31 was used to treat a
polyester satin fabric. The printed sample exhibited superior image
quality with little or no bleed, excellent ink retention, and
excellent color density. Permanence of color to washing was
dramatically increased without steaming or other steps. In
addition, sample possessed excellent color reflectivity.
Example 36
[0078] 50.7 wet parts cationic copolymer CP 7091 RV (ECC
International) (49.3% in water)(25 dry parts, or approximately 17%
of the total dry parts) was added to 993.5 parts water with mixing.
230.9 wet parts PrintRite.RTM. 591 acrylic emulsion (Noveon
Performance Coatings, 43.3% in water)(100 dry parts, or
approximately 68-69% of the total dry parts), and 296.3 wet parts
Varisoft.RTM. 475 fabric softener (6.8% in water) (20 dry parts, or
approximately 13-14% of the total dry parts) were added and the
entire solution was mixed until homogeneous. This formulation was
used to treat 100% silk charmeuse via a padding application and
dried. Wet pick-up was 140%. The sample was printed and evaluated
using the process described in Example 1. The printed sample
exhibited superior image quality with little or no bleed, excellent
ink retention, and excellent color density. Samples that were not
steamed exhibited good retention of color when washed. Samples that
were steamed exhibited excellent enhancement for color and
appearance. Permanence of color to washing was dramatically
increased compared to untreated samples. The Example utilized the
GS ink set.
[0079] Results of Trials 30-36
[0080] The printed images on the textile samples from Examples
29-35 were waterfast and exhibited acceptable lightfastness for
outdoor stability in accordance with ASTM test method G26 when
printed with Encad GO inks. AS.TM. test method G26 included the
following steps:
[0081] The standard practice under ASTM G26 for operating a
light-exposure (xenon-arc type) with and without water for exposure
of nonmetallic materials consists of the following procedures. Test
method 1 was employed for continuous exposure to light and
intermittent exposure to water spray. The type of apparatus used
consisted of an Atlas Ci 5000 apparatus. The instrument was
programmed for continuous light and intermittent water spray in
accordance with the manufacturer's instructions. The conventional
cycle of 102 minutes of light exposure followed by a cycle of 18
minutes of light and water spray was employed. Such sample data
measurements are reflected in the following Table 6. The method of
print mode is double strike, at 102 light, 18 min. spray after 6
hours.
6 TABLE 6 FR POLY. POPLIN L* A* B* DELTA E Black 1 29.0 1.7 -3.3
1.5 Cyan 60.6 -22.1 -38.5 4.2 Yellow 89.7 -9.0 64.4 14.5 Magenta
52.3 49.1 -10.0 2.6
[0082] From the experimental data it was determined that desirable
coatings by fabric type are as follows: Cotton Poplin and Jersey
Knit desirably use the coating described in Example 21 at about 13%
total solids; Silk Crepe de Chine and Charmeuse use the coating
described in Example 36 at about 7% total solids; Polyester
Georgette uses the coating described in Example 30 at about 32%
total solids; Poly Satin and Poly Dacron use the previous coating
(Example 30) at about 32% total solids; and Poly Poplin uses the
same coating at between about 20-25% total solids.
[0083] If textile post treatment is desired (i.e. a heating step,
such as steaming, oven heating, ironing, or other form of curative
step) a still further alternate embodiment of the present invention
relates to treatments/coating formulations and related methods for
treating textile substrates which enhance the color brilliance,
adhesion, and/or waterfastness/detergentfastness of inkjet reactive
dye, acid dye, and pigment based inks on textile fabric substrates,
which utilizes an imbibing solution in conjunction with a substrate
coating. For the purposes of this application, an imbibing solution
shall mean a solution used to saturate a fabric such that it
penetrates the interstitial spaces of the fabric. The coating
solution (or treatment, as has earlier been described) itself may
include the imbibing solution, or in the alternative, the coating
solution and imbibing solution may be applied in separate
application steps.
[0084] The treatment or coating formulations in the present
invention consist primarily of cationic polymers, binders, fabric
softeners, and other additives similar to those previously
described. However, in conjunction with these coating formulations,
an imbibing solution is used to further treat the fabric substrate.
For example, in a first embodiment utilizing the imbibing solution
with reactive ink sets, an imbibing solution consisting of either
sodium bicarbonate or sodium carbonate and urea, (for added color
brilliance with post-treatment) is used with an aqueous coated
fabric treatment. The imbibing solution is desirably applied at a
level of between about 5-20% by weight, more desirably 5-10% by
weight, depending on fabric type, and by using a standard
saturation/padding method When the imbibing solution is made a part
of the aqueous coating composition, desirably, the sodium
bicarbonate, sodium carbonate, or combination is present in the
imbibing/coating solution in an amount between about 3 and 10
percent of the total solids. Desirably, the urea is present in the
combined imbibing/coating solution in an amount between about 5 and
12 percent of the total solids. Other additives may be included in
the combined coating/imbibing solution such as wetting agents, and
defoamers. If additives are present in the formulation, they are
desirably present in an amount between about 0.1 and 1 percent of
the total solids. For instance, the wetting agent Q2-5211 may be
included in the combined coating/imbibing solution. Optionally, dye
fixatives may also be included in the coating formulation at less
than about 5% of the total solids.
[0085] When the imbibing solution is applied as a separate solution
following the coating formulation application, the sodium
bicarbonate/sodium carbonate is also desirably present in an amount
between about 30 and 40 percent of the total solids. The urea is
present in the separate imbibing solution in an amount between
about 50 and 70 percent solids. When the imbibing solution is used
as a separate solution from the coating formulation, it may also
include a wetting agent in solution as well as other additives in
the same amounts as the prior embodiment. Water is present in
solution in an amount between about 10 and 90 percent of the
solution. As has been stated, this imbibing solution embodiment is
desirably used with the reactive colorant classes, including those
which may be applied via ink jet printing processes such as the
monochlorotriazines and/or vinyl sulfones.
[0086] In a second embodiment utilizing an imbibing solution, the
aqueous imbibing solution includes ammonium sulfate and urea for
added color brilliance with post-treatment. As has been stated for
the previous embodiment, the imbibing solution may be a part of the
initial coating, or a separate solution. In this embodiment, the
ammonium sulfate is desirably present in an amount between about 5
and 10 percent of the total solids, when used as part of the
coating formulation. The urea is desirably present in the combined
coating/imbibing solution in an amount of between about 2 and 5
percent of the total solids. When the imbibing solution is a
separate solution from the coating solution, the ammonium sulfate
is present in an amount of between about 30 and 40 percent of the
total solids. The urea is present in this separate imbibing
solution in an amount between about 50 and 70 percent of the total
solids. Other additives may be included in the combined
coating/imbibing solution such as wetting agents, surfactants and
defoamers. For instance, the wetting agent Q2-5211 may be included
in the combined coating/imbibing solution. Optionally, dye
fixatives may also be included in the coating formulation at less
than about 5 percent of the total solids. To reiterate, when the
imbibing solution is used as a separate solution from the coating
formulation, the solution also includes water and optionally
wetting agents. The second embodiment is to be used with the acid
dye class including those which may be applied via ink jet printing
processes. The imbibing solution is desirably applied at a level of
5-20% by weight, depending on fabric type, and by using a standard
saturation/padding method. More desirably, the imbibing solution is
applied at a level of 10-15% by weight. It should be noted that
when the imbibing solution for the above described embodiments are
to be made separately from the coating formulation, they can either
be mixed in a 50/50 ratio with the coating formulation to be
applied simultaneously or in the alternative, the coating
formulation can first be applied to the fabric, the fabric dried,
and then the imbibing solution can be applied to the fabric and
then dried.
[0087] Textile substrates for use with the treatment methods may
include cotton, silk, linen, polyester, rayon, nylon, and blends
thereof. Conventionally, reactive dyes are used for cotton
substrates and acid dyes are used for silk and nylon substrates.
However, because of the coating treatment and fixation treatment
(imbibing solution) associated with it, the invention allows for
the fixation of classes of dyes on substrates that they are not
normally associated with, or which would not be done commercially
because the fixation is not normally facile or efficient. As
demonstrated by the set of examples which follow, the disclosed ink
jet receptive substrates that have been further treated with an
imbibing solution provide high color density and saturation,
superior print quality, reduction of wicking or bleeding, and
enhanced ink absorption. Furthermore, the coating or treatment
formulations provide a color enhanced waterfast/detergentfast
printed image when printed with an ink jet printing process with
post-printing treatment steps, such as heating, steaming, chemical
fixation, or radiation curing. With a conventional steaming
process, minimal dye washout occurs, thus minimal dyewaste
occurs.
[0088] This alternate embodiment of the present invention is
further described by the set of examples which follow. Such
examples, however, are not meant to be construed as limiting in any
way either the spirit or the scope of the present invention.
Example Conditions
[0089] A series of coatings were created including cationic
polymers, fabric softeners, latex binders, other additives and
water. The coatings are identified below with the respective
content percentages. It should be noted that certain coatings
included an imbibing solution within their formulation while others
did not, and an imbibing solution was therefore utilized in a
separate application step. Batch sizes are expressed in grams.
7 First Coating (similar to that used in the previous Example 21),
referred to as Types A, B & D in the examples which follow, for
use with cotton fabrics ORDER OF % BATCH ADDITION TOTAL DRY WET
SIZE INGREDIENTS SOLIDS PARTS PARTS (GRAMS) CP7091RV 49.30 18.50
37.53 18.01 AirFlex 540 55.17 37.00 67.07 32.19 PrintRite 591 43.50
37.00 85.06 40.83 Varisoft 475 10.00 7.40 74.00 35.52 Water 569.69
273.45 12 100 833.33 400
[0090]
8 Separate Imbibing Solution referred to as Type C for use with
cotton fabrics ORDER OF % ADDITION TOTAL DRY WET BATCH INGREDIENTS
SOLIDS PARTS PARTS SIZE Sodium Bicarbonate 63.40 3.00 4.73 22.70
Urea 95.00 5.00 5.26 30.81 Q2-5211 100.00 0.20 0.20 1.17 Water
58.34 341.49 12 8.2 68.33 Approx. 400
[0091] The Dyeset concentrations (Polyamines), designated as Dyeset
Conc. in the tables that follow, were obtained from Sybron
Chemicals of Wellford, S.C., along with Dyeset NOZ and Dyeset NFS.
Such materials are dye fixatives for reactive dyes. The Q2-5211
which is a wetting agent, was obtained from Dow Corning. The sodium
bicarbonate can be obtained from VWR of Norcross, Ga. and Baker
Chemical, and the Urea can be obtained from Baker Chemical.
9 The "Combo", which is a combination of a coating and imbibing
solution, referred to in the examples which follow as Type E, for
use with cotton fabrics. ORDER OF % ADDITION TOTAL DRY WET BATCH
INGREDIENTS SOLIDS PARTS PARTS SIZE CP709IRV 49.30 16.50 33.47
16.06 AirFlex 540 55.17 35.00 63.44 30.45 PrintRite 591 43.50 35.00
80.46 38.62 Varisoft 475 10.00 5.40 54.00 25.92 Sodium Bicarb 63.40
3.00 4.73 2.27 Urea 95.00 5.00 5.26 2.53 Q2-5211 100.00 0.20 0.20
0.10 Water 591.97 284.15 12 100 833.33 400
[0092]
10 Coating (similar to that of previous Example 21), referred to in
the following examples as Type F, used for cotton fabrics ORDER OF
% ADDITION TOTAL DRY WET BATCH INGREDIENTS SOLIDS PARTS PARTS SIZE
CP709IRV 49.30 17.50 35.50 17.04 AirFlex 540 55.17 36.00 65.25
31.32 PrintRite 591 43.50 36.00 82.76 39.72 Varisoft 475 10.00 7.40
74.00 35.52 Dyeset NOZ 12.20 3.00 24.59 11.80 Q2-5211 100.00 0.20
0.20 0.10 Water 551.23 264.59 12 100 833.33 400
[0093]
11 Coating, referred to in the examples that follow as Type G, used
for cotton ORDER OF % ADDITION TOTAL DRY WET BATCH INGREDIENTS
SOLIDS PARTS PARTS SIZE CP709IRV 49.30 17.50 35.50 17.04 AirFlex
540 55.17 36.00 65.25 31.32 PrintRite 591 43.50 36.00 82.76 39.72
Varisoft 475 10.00 7.40 74.00 35.52 Dyeset NFS 36.70 3.00 8.17 3.92
Q2-5211 100.00 0.20 0.20 0.10 Water 567.65 272.47 12 100 833.33
400
[0094]
12 Coating, referred to in the following examples as Type H for
cotton fabrics. ORDER OF % ADDITION TOTAL DRY WET BATCH INGREDIENTS
SOLIDS PARTS PARTS SIZE CP709IRV 49.30 17.50 35.50 17.04 AirFlex
540 55.17 36.00 65.25 31.32 PrintRite 591 43.50 36.00 82.76 39.72
Varisoft 475 10.00 7.40 74.00 35.52 Dyeset Conc. 47.60 3.00 6.30
3.03 Q2-5211 100.00 0.20 0.20 0.10 Water 569.52 273.37 12 100
833.33 400
[0095]
13 Coating, referred to in the following examples as Type H for
cotton fabrics ORDER OF % ADDITION TOTAL DRY WET BATCH INGREDIENTS
SOLIDS PARTS PARTS SIZE CP7091RV 49.30 15.50 31.44 15.09 AirFlex
540 55.17 34.00 61.63 29.58 PrintRite 591 43.50 34.00 78.16 37.52
Varisoft 475 10.00 5.40 54.00 25.92 Dyeset Conc 47.60 3.00 6.30
3.03 Sodium Bicarb 63.40 3.00 4.73 2.27 Urea 95.00 5.00 5.26 2.53
Q2-5211 100.00 0.20 0.20 0.10 Water 591.81 284.07 12 100 833.33
400
[0096]
14 Coating, referred to in the examples that follow as Type J for
cotton fabrics. ORDER OF % ADDITION TOTAL DRY WET BATCH INGREDIENTS
SOLIDS PARTS PARTS SIZE CP7091RV 49.30 15.50 31.44 15.09 AirFlex
540 55.17 34.00 61.63 29.58 PrintRite 591 43.50 34.00 78.16 37.52
Varisoft 475 10.00 5.40 54.00 25.92 Dyeset NOZ 12.20 3.00 24.59
11.80 Sodium Bicarb 63.40 3.00 4.73 2.27 Urea 95.00 5.00 5.26 2.53
Q2-5211 100.00 0.20 0.20 0.10 Water 573.52 275.29 12 100 833.33
400
[0097]
15 Coating referred to in the following examples as Type K for
cotton fabrics. ORDER OF % ADDITION TOTAL DRY WET BATCH INGREDIENTS
SOLIDS PARTS PARTS SIZE CP7091RV 49.30 15.50 31.44 15.09 AirFlex
540 55.17 34.00 61.63 29.58 PrintRite 591 43.50 34.00 78.16 37.52
Varisoft 475 10.00 5.40 54.00 25.92 Dyeset NFS 36.70 3.00 8.17 3.92
Sodium Bicarb 63.40 3.00 4.73 2.27 Urea 95.00 5.00 5.26 2.53
Q2-5211 100.00 0.20 0.20 0.10 Water 589.94 283.17 12 100 833.33
400
[0098] It should be noted that the above coatings can be used on a
variety of textiles including silk and nylon. Additionally, the
following coating can be used for Nylon/Lycra and silk substrates
when using acid dyes.
16 Coating, used for Nylon/Lycra and silk fabrics with acid dyes
sets ORDER OF % ADDITION OF TOTAL DRY WET BATCH INGREDIENTS SOLIDS
PARTS PARTS SIZE 5 Reten 204LS 17.95 25.00 139.28 452.62 2 AirFlex
540 55.27 100.00 181.26 589.06 3 V5475 10.00 20.00 200.00 649.97 4
Q2-5211 100.00 2.70 2.70 8.77 1.00 0.00 0.00 0.00 1.00 0.00 0.00
0.00 1 water 707.60 2299.58 12 147.7 1230.83 4000
[0099] The coating and imbibing solution may be poured together as
described below. The separate acid dye fixation formula (imbibing
solution, without coating solution) includes deionized water in the
range of about 30-90%, but more desirably at about 83 weight
percentage, ammonium sulfate in the range of about 2 to 40 total
solids percent, urea in the range of about 1 to 40 solids percent,
and an optional surfactant in the range of about 0.1-1.0, such as,
Surfynol 465 at about 0.2 weight percent. The acid dye fixation
formula described above (acid imbibing solution) is used with a
particular coating, such as coatings described to be similar to
preliminary Example 21 (described in the reactive dye section) or
the coating listed immediately above, by being poured into the
coating in a 50/50 ratio and then applied to the substrate as
previously described, as opposed to being applied in a separate
application step. For the silk substrate in particular, the coating
used was combined in a 50/50 ratio with the acid imbibing solution.
Alternatively, the coating and imbibing solution can be combined,
such as in the formulation described below.
17 Coating, used for Nylon/Lycra and silk fabric substrates, with
acid dyes sets, including both preliminary coating and imbibing
solution ORDER OF ADDITION OF INGREDIENTS % TOTAL DRY WET BATCH
NOTED BY NUMBER SOLIDS PARTS PARTS SIZE 7 CP7091RV 49.3 15.5 31.4
19.51 4 Airflex 540 55.17 34 61.6 38.25 6 PrintRite 591 43.5 34
78.2 48.51 5 Varisoft 475 10 20.4 204.0 126.62 3 Ammonium Sulfate
100 7 7.0 4.34 2 Urea 95 5 5.3 3.27 1 Water 584.4 362.75 12.00 116
966.67 600
Reactive Dye Examples
Example 1
[0100] In this and the following examples, 11 by 15 inch fabric
samples were evaluated. In example 1, the samples were first coated
and then imbibed. In particular, the fabric was first coated
through a dip and nip procedure/padding as has been previously
described, using coating A and then dried in a forced air oven at
100.degree. C. for 30 seconds. Following this step the fabric
sample was imbibed in a dip and nip/padding method using imbibing
solution C and dried again in the oven at 100.degree. C. for 30
seconds. For each example (except where otherwise noted) four
fabric sample sheets were tested. In order to achieve good hand
attributes, the goal for percent dry pickup was between 7 and 9.
The percent dry pickup was calculated in accordance with the
following series of equations. These equations are described in
Wellington Sears Handbook of Industrial Textiles, by Sabit Adanur,
PH.D.copyright 1995, p.179. 1 Wet pickup (%) = Weight of
formulation picked up Weight of dry fabric .times. 100 Add-on
(%)=Concentration of Formulation (%).times.Wet Pickup (%)
[0101] From this the following equation was utilized to arrive at
the values in the charts for % dry-pickup.
% Dry Pickup=((Wet/Basis Weight).times.100)-100.times.% Solids
(TS)
Results of Example 1
[0102]
18 OBJECTIVE: TO IMBIBE COTTON POPLIN FABRIC USING TYPE A COATING
AND SEPARATE IMBIBING SOLUTION. T.S.* OF 11.6 IN PERCENT # BW Dry
in grms/m.sup.2 Wet weight in grams % Pickup Dry 1 14.1 24.29 8.4 2
14.1 24.21 8.4 3 14.3 24.74 8.5 4 14.3 25.28 9.0 *T.S. represents
total solids (percent), BW represents basis weight.
Example 2
[0103] In this example fabric samples were imbibed first using
imbibing solution Type C and then coated with Coating Type B using
the procedures described in previous Example 1.
19 OBJECTIVE: TO IMBIBE COTTON POPLIN USING TYPE B WITH T.S.
11.6/T.S. 10.6 Imbibing Step T.S. 11.6 Coating Step T.S. 10.6
SAMPLE BW in Wet weight % Dry BW in Wet weight % Dry # grms/m.sup.2
in grms Pickup grms/m.sup.2 in grms Pickup 1 10.85 22.71 12.6 12.42
22.20 8.4 2 10.87 22.88 12.7 12.38 21.35 7.7 3 10.8 22.16 12.2
12.34 22.22 8.5 4 10.9 22.46 12.3 11.74 20.94 8.3
Example 3
[0104] In this example fabric samples were imbibed only with
solution Type C.
20 OBJECTIVE: TO IMBIBE COTTON POPLIN WITH SOLUTION TYPE C WITH
T.S. OF 12 Sample # BW in grms/m.sup.2 Wet weight in grms % Dry
Pickup 1 10.83 21.92 11.8 2 10.58 21.63 12.1 3 9.69 19.75 12.1 4
9.7 20.6 12.9
Example 4
[0105] In this example fabric samples were coated only with Type D
coating.
21 OBJECTIVE: TO COAT FABRIC SAMPLES ONLY WITH TYPE D/T.S. 10.6.
Sample # BW in grms/m.sup.2 Wet weight in grms % Dry Pickup 1 9.73
18.46 9.5 2 9.84 18.54 9.3 3 10.73 20.79 9.9 4 10.76 20.93 10.1
Example 5
[0106] In this example fabric samples were coated with the Combo
Type E solution.
22 OBJECTIVE: TO TREAT FABRICS WITH THE COMBO SOLUTION/T.S. 11.4,
TYPE E Sample # BW in grms/m.sup.2 Wet weight in grms % Dry Pickup
1 10.97 21.14 10.6 2 10.74 20.47 10.3 3 10.75 20.62 10.5
Example 6
[0107] In this example fabric samples were coated with Type F
coating.
23 OBJECTIVE: TYPE F COATING; DYESET NOZ AND T.S. 11.1 Sample # BW
in grms/m.sup.2 Wet weight in grms % Dry Pickup 1 10.84 21.7 11.1 2
11.02 21.29 10.3 3 10.87 21.26 10.7
Example 7
[0108] In this example fabric samples were treated with Type G
coating.
24 OBJECTIVE: TYPE G/DYESET NFS AND T.S. 11.68 Sample # BW in
grms/m.sup.2 Wet weight in grms % Dry Pickup 1 10.84 21.1 11.1 2
10.85 20.7 10.6 3 10.77 20.7 10.8
Example 8
[0109] In this example fabric samples were treated with Type H
coating.
25 OBJECTIVE: TYPE H/DYESET CONC T.S. 11.2 Sample # BW in
grms/m.sup.2 Wet weight in grms % Dry Pickup 1 10.86 21.1 10.5 2
10.86 21.3 10.6 3 10.86 20.6 10.4
Example 9
[0110] In this example fabric samples were treated with Type I
coating.
26 OBJECTIVE: TYPE I/CONC T.S. 11.4 Sample # BW in grms/m.sup.2 Wet
weight in grms % Dry Pickup 1 10.6 20.9 11.1 2 10.9 21.4 10.9 3
10.8 21.2 10.9
Example 10
[0111] In this example fabric samples were treated with Type J
coating.
27 OBJECTIVE: TYPE J/NOZ/T.S. 11 Sample # BW in grms/m.sup.2 Wet
weight in grms % Dry Pickup 1 10.98 21.4 10.5 2 10.78 21.2 10.6 3
10.72 20.73 10.2
Example 11
[0112] In this example fabric samples were treated with Type K
coating.
28 OBJECTIVE: TYPE K/NFS Sample # BW in grms/m.sup.2 Wet weight in
grms % Dry Pickup 1 12.2 24.1 11.7 2 12.2 23.8 11.4 3 10.7 20.8
11.3
Reactive Dye Example Results
[0113] Each of the samples were exposed on half of their area to
D65/10.degree. illuminant 10 (standard day light) to determine
whether any yellowing occurs. A sample of each was also printed
using the TX-1500 printer of Encad and a reactive ink set available
from Kimberly-Clark Printing Technology, Inc. of Escondido, Calif.
under the designations 17960-17970. Prior to printing, the fabric
sample was first laminated to a backing as has been previously
described in the first example set. Examples of reactive dyes used
included reactive blue 49 and black 5 available from companies such
as DyStar and BASF Corporation. The reactive dye sets utilize vinyl
sulfones and monochlorotriazines.
[0114] Since reactive dyes are typically not ink-jetted because of
the level of particulates and other salt components in the dyes, a
reactive dye set was developed for testing with the coatings. It is
surmised that other reactive dye sets could also be used in
conjunction with the coatings, such as those dyes available from
Ciba. The dyed samples were dried overnight in the dark.
[0115] Type A was demonstrated to work well only after it had been
steamed. Exposing Type A to a water wash was acceptable before
steaming but detergent wash demonstrated considerable washout. Type
B was demonstrated to work well without steaming but had some
redepositing problems onto the fabric. Type C was demonstrated as
having the most washout of all samples tested without steaming and
having a visually impaired appearance. After steaming the results
for Type C were very much improved. Type D demonstrated positive
results across all samples but failed the water spot test and
printed samples. Only after washing and/or after steam and washing
did Type D sample pass water spot testing. Type E demonstrated very
acceptable results with water spotting occurring on printed sample
only. Type E demonstrated poor results in detergent washing with no
post processing steps. Type F demonstrated positive visual
appearances as did Type H samples. Type G samples failed most
testing. Types I, J and K each demonstrated relatively the same
positive results, although type K was shown to be a better
performer in terms of appearance and washability.
[0116] For the purposes of this application the water spot test
comprised AATTC Test Method 104-1994. Essentially in this test, a
drop of water is placed on a substrate and then rubbed down using a
glass rod. The substrate is then observed to see if a water spot
remains after the water dries. If a white circle appears then a
water spot is considered to have been left.
[0117] Other reactive dye ink sets may be used with these coatings
including those available from Kimberly-Clark Printing Technology,
Inc. under the designations, TXCR-500 Black, TXCR-520 Red, TXCR-523
Medium Red, TXCR-526 Scarlet, TXCR-530 Orange, TXCR-540 Yellow,
TXCR-545 Golden Yellow, TXCR-550 Green, TXCR-560 Turquoise,
TXCR-565 Medium Turquoise, TXCR-570 Blue, and TXCR-580 Gray. These
reactive dye ink sets were tested with the above coatings by
printing them through a Colorspan DM XII 12-color printer/600
dpi.
[0118] Alternatively, instead of using reactive dye sets, acid dye
ink sets may be used with acid dye fixation solutions (Imbibing
solutions). Textile substrates which can use the acid dye sets
include ones such as those with fibers that are dyeable with acid
dyes, blended yarns, as long as the ratio is at least 15% between
nylon and other material such as Lycra, and polyamides. Such acid
dye sets are available from Kimberly-Clark Printing Technology,
Inc. under the designation 17972-17975. Additional acid dye sets
are available from Kimberly-Clark Printing Technology, Inc. under
the designations 7287-20-2 Black, 7287-27-2 Gray, 6869-184-5
Violet, 7287-21-1 Blue, 7287-24-2 Lt. Blue, 7287-10-1 Turquoise,
and 7287-25-1 Green, 6869-186-3B Magenta, 7287-24-1 Lt. Magenta,
6869-184-10 Scarlet, 7287-15-1 Orange, 7287-6-1 Yellow. Such inks
were tested with the above described coatings using the Colorspan
DM XII printer previously described.
[0119] By using such dye sets, an inkjet solution to a conventional
screen printing process using acid dyes and a treated substrate is
provided. Providing a digital alternative to this market will
greatly reduce the cost for the manufacturing of textiles and will
allow for more custom-made products to be produced.
Acid Dye Examples
[0120] A coated and imbibed nylon fabric was prepared in a similar
fashion to the fabric samples previously described, and printed
with a test print on the dried sample. The sample was washed in hot
water with no apparent dye washout.
[0121] In a second set of examples, acid dye sets were used on silk
charmeuse and on Nylon/Lycra fabric samples. As in the prior
examples, fabric sheet swatches of 11 by 15 inches were cut of the
fabric, and the fabric was then tested in accordance with various
test coatings. It should be noted that these fabrics can not be
printed on directly while uncoated. The results for just washing
demonstrates a Delta E of 40 for nylon/Lycra and a Delta E of 35
for the silk charmeuse without post treatment. However, following
post treatment for coated fabrics the Delta E values for both were
about 1.5 or less. Post treatment consisted of steaming, and in
particular, steaming the fabrics at between about 105.degree. C. to
125.degree. C., approximately 25 minutes for silk and 45 minutes
for nylon/lycra. The following Table 7.
29 TABLE 7 ACID INKS ON SILK, STEAMED USING KIMBERLY-CLARK AND
PRINTING TECH. STEAMED WASHED INKS (COLOR) DELTA E DELTA E Yellow
8.9 0.5 Orange 7.1 0.5 Scarlet 17.2 1.5 Med. Scarlet 8.3 2.4
Magenta 19.2 1.5 Green 6.2 1.3 Med. Trq. 4.1 1.5 Trq. 4.9 0.7 Blue
5.3 1.9 Violet 6.6 0.8 Grey 3.4 1.2 Black 4.5 0.4
[0122] In a further alternative embodiment, it has been determined
that a coating/imbibing formulation including ammonium salts of
multifunctional weak acids, selected from the group consisting of
ammonium oxalate from Aldrich and ammonium tartrate. Such
coating/imbibing formulations desirably include ammonium oxalate as
a particularly effective coating component for treating nylon/lycra
fabric substrates, present in the same amount as in the previous
ammonium sulfate examples. However, use of such ingredient in the
formulation tends to create "cross-hatching" in the printed image.
In order to eliminate this cross-hatching for nylon/lycra
substrates, it has been determined that the addition of tanning
agents eliminates this problem. Such tanning agents are exemplified
by ethylene glycol monoethyl ether, and thiodiethylene glycol as
described in the following coating formulations. Such tanning
agents are available from Aldrich of Milwaukee, Wis. If used, it is
desirable that such tanning agents be present in the coating
formulation in an amount of between about 0.5 and 10% of total
solids.
30 Ammonium Oxalate Coating, used for Nylon/Lycra and silk fabric
substrates, with acid dyes sets, including both preliminary coating
and imbibing solution ORDER OF ADDITION % TOTAL DRY WET BATCH
INGREDIENTS SOLIDS PARTS PARTS SIZE 7 CP7091RV 49.3 15.5 31.4 19.51
5 Airflex 540 55.17 34 61.6 38.25 6 PrintRite 591 43.5 34 78.2
48.51 4 Varisoft 475 10 20.4 204.0 126.62 2 Ammonium Oxalate 100 7
7.0 4.34 3 Urea 95 5 5.3 3.27 1 Water 584.4 362.75 12.00 116 966.67
600
[0123]
31 Expanded Ammonium Oxalate Coating, used for Nylon/Lycra and silk
fabric substrates, with acid dyes sets, including both preliminary
coating and imbibing solution ORDER OF ADDITION % TOTAL DRY WET
BATCH INGREDIENTS SOLIDS PARTS PARTS SIZE Water 377.4 231.83
Ammonium Oxalate 100 7 7.0 4.30 Urea 95 5 5.3 3.23 Thiodiethylene
Glycol 100 3 3.0 1.84 Ethylene Glycol 100 2 2.0 1.23 monoethyl
ether Varisoft 475 10 17 170.0 104.43 Airflex 540 55.17 29 52.6
32.29 PrintRite 591 43.5 29 66.7 40.95 CP7091RV 49.3 13 26.4 16.20
15.00 105 700.00 430
[0124] Desirably, the ammonium oxalate is present in the
coating/imbibing formulation in an amount similar to that of
ammonium sulfate (as described in the previous examples). In
running a Crockfastness test, that is Test Method 8 of the AATCC,
described in the AATCC manual, Color Technology in the Textile
Industry, 2.sup.nd Edition, Published 1997 by AATCC (American
Association of Textile Chemists & Colorists), it was determined
that such cross-hatching is eliminated by the use of ammonium
oxalate in combination with tanning agents. This test demonstrated
pass results for the rubbing of a substrate with a known cloth to
look for ink rub off. This done is performed both wet and dry.
Pigment Ink Examples
[0125] It should also be recognized that Pigmented Ink Formulations
may also be used in conjunction with the coating and imbibing
solution formulations. It is particularly desirable to use
Pigmented Ink formulations available from Kimberly-Clark Printing
Technology, Inc. under the designations 17976-17979. Examples of
the pigment dispersions include Acryjet Cyan, majenta, yellow and
black available from the Rhom and Haas Corporation.
[0126] The coating/treatment formulations and methods which are the
subject of this invention, provide ink jet printable textile
substrates which possess characteristics of print and image
quality, a noticeable color enhancement, color quality and density,
ink retention capacity, and waterfastness and detergentfastness
properties. Such formulations can be used to prepare articles of
manufacture as previously described.
[0127] While the invention has been described in detail with
particular reference to a preferred embodiment thereof, it should
be understood that many modifications, additions, and deletions can
be made thereto without departure from the spirit and the scope of
the invention as set forth in the following claims.
* * * * *